Pillow stuffed with latex foam crumbs

ABSTRACT

A method of manufacturing a pillow, comprising the steps of granulating pieces of latex foam to produce a variety of sizes of latex foam crumbs; passing the crumbs through a screen to generally exclude most latex foam crumbs which are greater than a predetermined nominal diameter; filling a pillow casing with the screened crumbs; and sealing the casing shut to capture the latex foam crumbs. The screen optimally has apertures approximately ⅜ inch (9.5 mm) in diameter to produce a pillow comprising a casing filled with latex foam crumbs where the latex foam crumbs are in a variety of sizes, generally not exceeding about 1 inch (25.4 mm) in nominal diameter.

BACKGROUND OF THE INVENTION

[0001] This invention relates to pillows, and more precisely to the filling used inside the pillow casing.

[0002] A pillow typically consists just of a sewn outer casing or “ticking”, which may for example be of cotton, polyester, or blends of same, along with many other possible materials. Prior to being sewn shut, the outer casing is stuffed with feathers, down, polyester fill, a latex foam block, or a wide variety of other materials.

SUMMARY OF THE INVENTION

[0003] In the invention, chunks of latex foam, for example scrap left over from latex foam mattress production, are put through a granulator, and are then screened to provide an irregular mixture of relatively small latex foam rubber particles, which are then used to fill the pillow casing.

[0004] Preferably the screening is conducted through holes which are ⅜ inch (9.5 mm) in diameter. This provides a suitable size distribution of particles to provide the desired feather-like feel for the pillow. If the chunks are too small, then there is too much compaction and the pillow becomes quite hard. On the other hand, if the chunks are too large, discrete pieces can be felt, i.e. the pillow has a lumpy feel for the user. Although it is not essential that the ⅜ inch screen size be used, this size has been found to be optimum, in the inventor's opinion. Note that the ⅜ inch screen size does not necessarily limit the size of the crumbs to ⅜ inch, since some larger pieces can be compressed and forced through the holes, but the ⅜ inch holes provide a good mixture of sizes.

[0005] Thus, a pillow is produced according to the invention, wherein the latex foam crumbs are in a variety of sizes, generally not exceeding about 1 inch (25.4 mm) in nominal diameter. A certain amount of slightly over-size crumbs will be pushed through the screen openings, as detailed above, due to the compressible nature of the latex material of the crumbs.

[0006] Preferably, the weight of latex foam crumbs for a standard-sized pillow having a casing approximately 26 cm×36.5 cm when empty and flat is in the range of 2.0-3.3 lbs (0.91-1.50 kg). Optimally, the weight of latex foam crumbs is approximately 2.7 lbs (1.23 kg).

[0007] Preferably, the weight of latex foam crumbs for a queen-sized pillow having a casing approximately 30 cm×36.5 cm when empty and flat is in the range of 2.5-3.6 lbs (1.13-1.63 kg). Optimally, the weight of latex foam crumbs is approximately 3.1 lbs (1.41 kg).

[0008] Preferably, the weight of latex foam crumbs for a king-sized pillow having a casing approximately 35 cm×36.5 cm when empty and flat is in the range of 3.0-4.5 lbs (1.36-2.04 kg). Optimally, the weight of latex foam crumbs is approximately 3.7 lbs (1.68 kg).

[0009] A method of manufacturing a pillow according to the invention comprises the steps of:

[0010] granulating pieces of latex foam to produce a variety of sizes of latex foam crumbs;

[0011] passing the latex foam crumbs through a screen to generally exclude most latex foam crumbs which are greater than a predetermined nominal diameter;

[0012] filling a pillow casing with the screened latex foam crumbs; and

[0013] sealing the casing shut to capture the latex foam crumbs.

[0014] The screen preferably has apertures approximately ⅜ inch (9.5 mm) in diameter to let through the screen only latex foam crumbs generally not exceeding about 1 inch (25.4 mm) in nominal diameter.

[0015] Preferably, the sealing step is performed by sewing the casing shut. Alternatively, the casing may be glued, fused, zippered or riveted shut, for example.

[0016] Further features of the invention will be described or will become apparent in the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention will now be described in detail with reference to the accompanying drawings of the preferred embodiment, in which:

[0018]FIG. 1 is a cut-open perspective view of a pillow according to the invention; and

[0019]FIG. 2 is a block diagram of the method of manufacturing the pillow.

DETAILED DESCRIPTION

[0020]FIG. 1 shows a pillow 1 having an outer casing or ticking 2, filled with latex foam crumbs 3.

[0021]FIG. 2 shows the method of manufacturing the pillow, in which latex foam blocks (scrap pieces, for example) are put through a granulator, i.e. a comminution device typically of the type having counter-rotating knives, to break the blocks into small pieces. The granulated pieces are then screened, preferably through holes which are ⅜ inch (9.5 mm) in diameter. As discussed above, the hole size could be varied as desired, but this particular hole size is believed to be optimum. This process produces a mixture of sizes, from slightly over ⅜ inch, down to bread-crumb size. This mixture provides a very comfortable overall texture, which deforms and shifts to a desirable degree, while still remaining somewhat resilient.

[0022] Another factor in producing the desired “feel” for the pillow is how much of the granulated and screened latex foam is inserted into the pillow, i.e. the overall density. The inventor has found that the following weights are optimum, though obviously these weights could be varied according to personal preference and the particular material used for the crumbs: Casing Weight of latex foam crumbs, in lbs dimensions Minimum Maximum when empty and for soft for hard Pillow size flat (cm.) pillow Optimum pillow Standard 26 × 36.5 2.4 2.7 3.0 Queen 30 × 36.5 2.8 3.1 3.4 King 35 × 36.5 3.4 3.7 4.0

[0023] Note that in the above table, the “minimum” and “maximum” numbers should not be interpreted to mean that numbers outside those ranges are not possible. They merely indicate the inventor's preference. In the inventor's opinion, weights outside the above ranges will not be ideal for marketing, but they may appeal to certain individual preferences.

[0024] It will be appreciated that the above description relates to the preferred embodiment by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described.

[0025] For example, latex foam material has been described as being the preferred material. Any material having suitable properties equivalent to foam latex may be used. A further advantage cost-wise is to use scrap material, which reduces material cost and increases the positive environmental impact of the manufacture of pillows according to the invention. 

1. A pillow comprising a casing filled with latex foam crumbs.
 2. A pillow as recited in claim 1, wherein said latex foam crumbs are in a variety of sizes, generally not exceeding about 1 inch (25.4 mm) in nominal diameter.
 3. A pillow as recited in claim 1, wherein the weight of latex foam crumbs for a standard-sized pillow having a casing approximately 26 cm×36.5 cm when empty and flat is in the range of 2.0-3.3 lbs (0.91-1.50 kg).
 4. A pillow as recited in claim 3, wherein the weight of latex foam crumbs is approximately 2.7 lbs (1.23 kg).
 5. A pillow as recited in claim 1, wherein the weight of latex foam crumbs for a queen-sized pillow having a casing approximately 30 cm×36.5 cm when empty and flat is in the range of 2.5-3.6 lbs (1.13-1.63 kg).
 6. A pillow as recited in claim 5, wherein the weight of latex foam crumbs is approximately 3.1 lbs (1.41 kg).
 7. A pillow as recited in claim 1, wherein the weight of latex foam crumbs for a king-sized pillow having a casing approximately 35 cm×36.5 cm when empty and flat is in the range of 3.0-4.5 lbs (1.36-2.04 kg).
 8. A pillow as recited in claim 7, wherein the weight of latex foam crumbs is approximately 3.7 lbs (1.68 kg).
 9. A method of manufacturing a pillow, comprising the steps of: granulating pieces of latex foam to produce a variety of sizes of latex foam crumbs; passing said latex foam crumbs through a screen to generally exclude most latex foam crumbs which are greater than a predetermined nominal diameter; filling a pillow casing with said screened latex foam crumbs; and sealing said casing shut to capture said latex foam crumbs.
 10. A method as recited in claim 9, wherein said screen has apertures approximately ⅜ inch (9.5 mm) in diameter to let through said screen only latex foam crumbs generally not exceeding about 1 inch (25.4 mm) in nominal diameter.
 11. A method as recited in claim 9, wherein said sealing step is performed by sewing said casing shut. 